Increasing Batch Size And Reducing Cycle Times For A Biologic

A long-standing partner engaged JHS to explore ways to reduce cycle times for a biologic drug, aiming to serve more patients more efficiently. JHS had collaborated with this top 20 global pharmaceutical company for over 15 years on the same product, making them well-positioned to drive process improvements.

The joint effort began with a detailed process mapping exercise, analyzing every step from API receipt to final inspection and packaging. This collaborative review identified bottlenecks, inefficiencies, and opportunities to streamline workflows. Both organizations implemented the recommended changes, focusing on process optimization, scheduling improvements, and operational coordination.

The results were significant. JHS increased annual output by approximately 50% while cutting batch release timelines by an average of 9–17 days. Given that the average batch release time for a monoclonal antibody is about 60 days, these improvements represented a 15–30% reduction in turnaround time. This efficiency gain meant more product reached patients faster without compromising quality or compliance.

The case underscores how long-term partnerships and collaborative problem-solving can unlock substantial productivity gains in pharmaceutical manufacturing. By combining process expertise, operational discipline, and shared commitment to patient outcomes, JHS and its partner developed sustainable improvements that expanded production capacity and improved delivery timelines. The initiative not only met immediate operational goals but also established a foundation for future efficiencies, ultimately benefiting patients who rely on this critical therapeutic.